C619 15T Rebond Block Foam Foaming Machine 33.5kW 15m³ Tank 4 Blocks/h for Waste PU Foam Recycling

The C619 rebond block foam foaming machine turns mixed foam waste into dense, reusable rebond blocks.

 Product Introduction

This machine primarily mixes crushed PU, EVA, PE, and rubber with binder under pressure, utilizing steam and then natural drying to foam blocks of rebond sponge, which are then sliced into sheets or blocks by a cutting machine. The cut products are mainly used in industries such as fitness equipment cushions, sports mats, wrestling mats, judo mats, cattle bedding, furniture, automotive, and footwear materials.

This foaming machine overcomes the drawback of significant density variations in traditional rebond foaming machines, enabling the production of uniformly dense rebond products. A single machine can produce two sizes, eliminating the hassle of changing molds to adjusting the finishing foam dimensions. It offers higher production efficiency and superior product quality.

This machine is a newly developed and improved equipment exclusively designed by Xinmei.

Rebond foam production starts with waste. Trimmings from foam cutting lines, offcuts from mattress and furniture factories, rejected moulded parts and post-industrial sponge scrap all contain valuable polymer that can be returned to production instead of being landfilled. The first step is size reduction: a shredder or grinder cuts the waste into granules of a controlled size. The granules then need to be bonded back into a solid block, and that is where the C619 comes in.

The C619 takes the granulated foam and mixes it with a binder inside a 15m³ mixing tank. The 33.5kW motor drives the mixing action so that binder is distributed across the whole batch rather than concentrated in one area. The mix is then transferred to the foaming tank, where it is compacted under pressure into a block. After curing, the block goes to a cutting machine, where it is sliced into sheets, pads or profiles for the end application.

Because the block is the starting point for every downstream sheet, block quality decides the yield of the whole line. A block with uneven density produces sheets with uneven hardness, and thin slices cut from a poor block tend to tear, crush or spring back differently from one end to the other. The C619 is designed to remove that variation at the source.

On conventional rebond foaming equipment, material is often fed into the foaming tank from a single point and compressed in one pass. The result is a block that is lighter at the top and denser at the bottom, because the binder and granules settle differently through the height of the block. Buyers notice the difference immediately when they slice the block: the top sheets are softer and lighter, the bottom sheets are harder and heavier, and the same nominal thickness behaves like two different products.

The C619 addresses this with controlled mixing before foaming and controlled compaction during block forming. The density tolerance is held to ±5kg/m³, and the maximum density is ≤120kg/m³. In practice this means a block can be sliced through its full height and deliver predictable hardness, predictable weight per sheet and predictable compression behaviour. Factories that laminate rebond foam, die-cut fitness mats or assemble cattle mattresses gain a stable input instead of sorting sheets by feel.

• Consistent hardness: sheets from the top and bottom of the same block perform alike.
• Higher slicing yield: fewer rejects when thin sheets are cut from the block.
• Predictable weight: easier costing, packing and container loading.
• Repeatable batches: the same recipe produces the same block, shift after shift.

Density is controlled by three variables that the operator can manage: the granule size distribution, the binder dosage and the compaction cycle. The C619 gives stable mechanical conditions for all three, so the recipe that is validated during commissioning can be repeated in daily production.

Changing block size normally means changing moulds, which costs time, labour and floor space. The C619 avoids that. One single foaming tank can produce two different foam sizes without replacing the mould, so a plant can switch between a thicker block for mattress cores and a thinner block for mat production in the same shift. Size adjustment is simplified and production efficiency stays high.

The foaming tank dimensions are customized at order. Two optional dimensions are available, and the correct choice depends on the block size your downstream cutting machine handles, the container loading plan and the density you need to reach. Sharing your target block dimensions with our engineers before the order is fixed is the fastest way to get a tank configuration that matches your product mix.

The C619 is built around four functional areas that work as one line.

The 15m³ tank is the heart of the machine. Its volume allows a full production batch to be blended in one charge, which is important for density consistency. The tank is driven by the main motor and is designed for thorough distribution of binder through the granule mix.

A 33.5kW motor provides the power for the mixing cycle. The drive is matched to the tank volume and the working load of a full batch, so the machine holds its speed when the tank is loaded rather than slowing down and leaving dead zones in the mix.

The foaming tank receives the mixed material and forms it into a block under pressure. Its dimensions are customized, with two optional sizes, and it is the component that determines the footprint of the finished block.

The machine weighs 15T and has an overall dimension of 7000×4000×5400mm. The structure is built to carry a full tank and a loaded foaming tank without deflection. Guards cover the moving parts, and the control panel groups the mixing cycle, the discharge sequence and the safety interlocks in one place so the operator can run the batch from a single station.

The C619 processes crushed PU foam, PE foam, EVA and rubber scraps. These materials behave differently in the tank: PU foam is light and compresses easily, EVA is denser and tougher, PE foam has a closed-cell structure and rubber scrap adds weight and hardness. The mixing action has to distribute binder across all of them, and the compaction cycle has to bring the mix to a stable block regardless of the blend.

Three practical rules keep quality stable:

• Control granule size. A consistent granule size gives a consistent surface area for the binder and a more even block. Oversized pieces create soft spots and weak zones.
• Remove foreign matter. Metal, stone, wood and hard plastic must be removed before the material reaches the mixing tank. They damage the block and can damage downstream cutting blades.
• Keep moisture under control. Wet scrap changes the binder ratio and can cause steam pockets or soft centres in the block. Store granulated material under cover and blend batches from different sources.

Binder dosage is set during commissioning against your own material mix. Once the recipe is fixed, the operator should weigh each batch and record the dosage so that a block can be traced back to its batch. This simple record is the foundation of consistent density and of any later customer complaint investigation.

• Uniform foam density: density tolerance ±5kg/m³, solving the upper-lower density deviation of traditional rebond foaming machines.
• Two sizes in one tank: produce two different foam sizes without replacing the mould, reducing changeover time and tooling cost.
• Multi-material input: process crushed PU foam, PE foam, EVA and rubber scraps with binder.
• High production efficiency: rated output of four blocks per hour with stable finished foam quality.
• Large batch capacity: a 15m³ mixing tank supports full-batch blending for repeatable density.
• Global support: remote technical assistance, spare parts supply and installation guidance after delivery.

Rated capacity is measured with matched upstream granule supply, a stable binder recipe and the specified block size. Actual output depends on block dimensions, target density, material blend and operator practice.

Density is the number that customers use to judge a rebond block, so it deserves a fixed routine rather than an operator judgement call. The C619 makes that routine possible because the mechanical conditions are stable.

Weigh the granulated material for each batch instead of filling the tank by volume. Volume filling hides differences in bulk density between PU, EVA and PE scrap, and those differences show up later as density variation in the block.

Use the dosage validated at commissioning and adjust only when the material source changes. Record the dosage on the batch card together with the material blend.

Keep the cycle time fixed. Shortening the cycle to gain output usually costs density at the bottom of the block, which is exactly the defect the machine is designed to avoid.

Cut a sample from the top and the bottom of the first block of each shift and weigh it. If the difference leaves the ±5kg/m³ window, check granule size, binder dosage and cycle time in that order.

Rebond foam blocks from the C619 are cut into sheets and profiles for applications where cushioning, energy absorption and durability matter more than surface finish.

• Fitness industry: gym mats, wrestling mats, judo mats and protective fitness cushions.
• Livestock: cow mattresses and cattle bedding, where a dense, dimensionally stable block resists compression under animal weight.
• Furniture: cushion cores, seat pads and upholstery support layers.
• Automotive: interior foam components, sound insulation pads and trunk liners.
• Footwear: shoe soles, midsoles and padding materials.
• Packaging and construction: protective padding, gym flooring underlay and impact-absorbing panels.

Because the block density is uniform, the same block can serve more than one of these markets. A plant can cut part of a block into mat sheets and part into furniture cushion cores without sorting or re-grading the foam.

The C619 is one link in a complete recycling line, and it works best when the upstream and downstream equipment are sized to match it.

Foam waste must be reduced to granules before it reaches the mixing tank. A shredder handles bulky pieces and blocks, while a grinder brings the material down to a consistent granule size. The output of the grinder should be slightly higher than the consumption of the C619 so that the foaming machine never waits for material.

This is where loose granules become a saleable block. The 15m³ tank and 33.5kW drive allow full batches to be mixed and compacted at a steady rate of four blocks per hour.

Blocks are normally cut on a CNC foam cutting machine with an oscillating blade or a band knife, then laminated, die-cut or packed. The block quality set by the C619 determines how well the cutting machine performs: a uniform block cuts cleanly at thin thicknesses, while a block with hard and soft zones forces the operator to slow down and accept rejects.

Plants that already run shredders and cutting machines can add the C619 without rebuilding the rest of the line. Plants starting from scratch should plan the three stages together so that capacity, floor space and power are balanced from the beginning.

The rated capacity is four blocks per hour. In an eight-hour shift this corresponds to roughly thirty-two blocks under stable conditions, before allowance for cleaning, material changes and breaks. Real output depends on four factors:

• Block size: larger foaming tank dimensions consume more material per block.
• Target density: a denser block needs more material and a longer compaction cycle.
• Material blend: mixes with a high share of EVA or rubber take longer to blend than light PU foam.
• Upstream supply: the grinder must keep pace with the mixing cycle, or the machine idles.

For planning, use four blocks per hour as the design figure and then adjust with your own block size and density. If your downstream cutting line consumes a fixed number of sheets per day, work backwards from the sheet count to the number of blocks, then to the number of shifts the C619 needs to run. This avoids buying capacity you cannot feed or creating a bottleneck at the cutting machine.

Conventional machines are usually evaluated on price per kilogram of output. On that measure the C619 is competitive, but the more important difference appears later, in the yield of the cutting line.

• Density profile: conventional single-point filling tends to produce a lighter top and a denser bottom; the C619 holds ±5kg/m³ across the block.
• Size changes: conventional machines often need a mould change to switch block size; the C619 produces two sizes in one tank without a mould change.
• Batch repeatability: a 15m³ tank and a fixed compaction cycle make the recipe repeatable, while smaller or manually loaded machines depend heavily on the operator.
• Material flexibility: the C619 handles PU, PE, EVA and rubber scrap in the same tank, so a plant can buy waste by availability rather than by type.

The practical result is fewer rejected sheets, less rework and a more predictable cost per square metre of finished foam. For a plant that sells cut sheets rather than blocks, that difference usually outweighs the purchase price within the first year of operation.

The machine weighs 15T and occupies an overall dimension of 7000×4000×5400mm, so plan the layout before the equipment arrives.

• Foundation: a level, load-bearing concrete floor capable of supporting the machine and a full batch. Our engineers provide a foundation drawing for the final configuration.
• Space: clearance around the machine for material loading, block removal and maintenance access, plus space for granule storage and binder storage.
• Power: a supply sized for the 33.5kW motor with correct starting protection. Confirm your local voltage and frequency with our engineers before the order is finalized.
• Ventilation and housekeeping: foam dust and binder vapours need airflow. Keep granulated material dry and away from ignition sources.

Installation follows a fixed sequence: foundation and leveling, alignment of the mixing and foaming sections, electrical connection, dry run without material, trial batch with clean granulate, density trial, then operator training and acceptance. Commissioning with your own material is the only reliable way to fix the binder recipe and the compaction cycle.

The C619 is a heavy industrial machine and should be operated by trained staff only. The control system interlocks the mixing cycle, the discharge and the foaming sequence so that the machine cannot be started with a guard open.

• Before each shift: inspect guards, check the emergency stop, confirm the tank is clean and empty, and verify that the material batch is correctly weighed.
• During production: keep the working platform clear, never reach into the tank while the drive is running, and record density samples from the first block.
• Lockout: isolate power before any work inside the tank, on the drive or on the discharge system.
• PPE: dust masks, eye protection and gloves when handling binder and granulated foam.

Operator training covers the batch recipe, the start and stop sequence, density sampling, daily cleaning and the reporting of abnormal noise or vibration. A trained operator is the difference between a machine that repeats its rated output and one that drifts as soon as the material changes.

Rebond foam is abrasive and sticky, so maintenance is mostly about cleanliness and inspection rather than major overhauls.

• Daily: clean the mixing tank, the discharge path and the foaming tank at the end of the shift. Cured binder is difficult to remove once it sets.
• Weekly: check the drive belt tension, fasteners and guard fixings; inspect the tank lining for build-up.
• Monthly: check motor current against the commissioning record, inspect seals and bearings, and verify the control interlocks.
• Spare parts: keep seals, fasteners, sensors and a set of wear liners in stock so that a minor fault does not stop the line for a week.

After-sales support includes remote technical assistance, spare parts supply and installation guidance. For plants that are new to rebond foam production, we recommend a scheduled review after the first month of operation to confirm the binder recipe and the density routine.

Each machine is assembled and run before shipment. The pre-shipment check covers the drive system, the mixing and discharge sequence, the control interlocks and the safety guards. The machine is CE certified.

For transport, the machine is cleaned, protected against corrosion and packed for container or flat-rack shipment according to the final configuration. Because the machine is 15T and more than seven metres long, the shipping plan is prepared together with the order so that lifting points, container type and unloading equipment are agreed before dispatch. Delivery time is 45 working days after downpayment, and the exact schedule is confirmed when the order is placed.

Three decisions shape the configuration of a C619 order:

1. Block size. Choose the foaming tank dimension from the block size your cutting machine and your customers require. Two optional dimensions are available, and the tank is customized at order.
2. Capacity fit. Match four blocks per hour against the output of your shredder and the demand of your cutting line. If the cutting line is the bottleneck, extra foaming capacity will sit idle.
3. Material mix. Tell us the share of PU, PE, EVA and rubber scrap in your waste stream. The binder recipe and the compaction cycle are set against that mix during commissioning.

Send us your target block size, target density, required daily output and available power supply. We will confirm the foaming tank option, the 33.5kW drive configuration and the delivery schedule in one proposal.